Manufacture of plastic-fiber composition



vC- C. HERITAGE MANUFACTURE OF PLASTIC-FIBER COMPOSITION Original Filed Nov. 13, `1944.A

Mmhy 6, 1951 Patented Mar. 6, 195i MANUFACTURE OF PLASTIC-FIBER COMPOSITION Clark C. Heritage, Cloquet, Minn., assignor to Wood Conversion Company, St. Paul, Minn., a corporation oi' Delaware Original application YNovember 13, 1944, Serial No. 563,209. Divided and this application June 21, 19.45, Serial No. 600,696

8 Claims.

This invention relates to compositions of plastic and fibers. One object of the invention is to provide improved methods of manufacturing flber containing molding material for the plastics art,

material may be employed without loss. Commonly, such drying involves heat which unfavorably advances a thermosetting resin binder, and

causes water-soluble resin to migrate to the surpreferably in sheet form and with fibers consist- 5 faces, thus introducing difliculties into the whole ing principally of celluloseV or' ligno-cellulose process. fibers such as wood fibers.v In the accompanying drawing Fig. 1 is a dia- Another object of the invention is to provide a grammatic view of one form of apparatus with novel plastic-'fiber composition in' a form that is which the improved method may be carried out. convenient to handle, being rigid or flexible, and l Fig. 2 is a sectional view of a preformed article which can readily be cut to size for use in molding of the improved molding material. dies used in thev plastics art. Fig. 3 illustrates an article formed from the The improved method of making the novel preform shown in Fig. 2. composition is characterized by intermixing dry In carrying out the improved process, cellulose fibers with a binder to provide initially a fiber l or ligne-cellulose fibers are employed. The bers mat of low density within which the binder maare individualized and dispersed in gas, such as terial is distributed in Particle or other finely air, by any suitable means such as a Prater mill, divided form or even as coatings on the iibers. or other fiber or dispersing apparatus into which The binder material when present as loose palan adequate stream of air is delivered to provide ticles. distributed within the iiber mass or met. an air vsuspension of the substantially individualis suitably activated to produce adherence of the ized fibers. Fiber stock may be passed through binder material to the fibers to prevent displacea blower or through suitable brush rolls to furment or migration of the particles Within the ther individualize the fibers and provide an air mat, or loss from themat, and toV impart to the dispersion thereof. Dry Vfibers are preferred. mat a strength above that afforded by the initial Air-dry fibers have about 10% moisture content, felting of the fibers resulting from the original and this may be increased to an appreciable mat formation. The mat is thereafter prefermoistness, thus to weight the fibers and aid or ably densified or preformed to provide a body of control the felting thereof, or guard against the convenient form for molding purposes.A The dedanger of static electricity. gree oi' preforming or densification may be varied 30 To the fiber dispersion or during the fiber dis.. depending on the intended modes of use, but genpei-sing process effected by the apparatus emerally the preformed material will be in `slab'or ployed, a suitable and preferably a matrix-form- Sheet form. or in Special shapes. for fitting in dies ing quantity of binder is addedin finely divided used in finally forming the finished molded form. The binder may be Such as to give rearticles. The density of the preformed material as quired'characteristics to the final molded product Preferably is less than that which gives rigidity t0 but preferably is a heat softenable material, the material, but is sufficient to reduce substanwhich becomes suitably plastic and tacky or adtially the initial bulk. of the fiber mass and herent upon being heated, even though such contheleby Provide o molding composition that iS dition be temporarily, as in the case of thermosufciently tenacious to withstand handling wltho setting resins. Suitable materials are: a pheout disintegration, and is not too bulky to be used satisfactorily in conventional plastic forming i 'Ihe improved method is distinguishable generally from common prior methodsv of molding dense cellulose fiber productsin that in forming the initial nber mat with interspaced binder material, such as particles, an air dispersion rather than a water suspension of the fibers vis utilized, and hence the process steps Vinvolved indrying` the fibers deposited from a water suspension are avoided by the present improvements, and bulkier nolic-aldehyde resin, gilsonite, pitch, natural and petroleum asphalts and resins, rosin, ester gum, abietic acid, shellac, protein-base compositions and many other natural and synthetic resins and their derivatives, and like materials, which are normally solid when cold, adhesive when hot. and are either thermoplastic or thermosetting when heated. l

The finely divided binder or matrix-formin material is added to or is present in the gaseous fiber dispersion for effecting 'a uniform distribution of the binder materials within the initially formed low-density ber mat. The binder material may be added in finely divided form to loose initialmats may be felted. Water-soluble binder 5| wood fibers, and an air dispersion of the mixture may be eected for deposition upon a suitable fiber-receiving member. If desired the binder in normally solid form may be introduced into a deiiberizing machine for comminution thereby concurrently with the individualization of the fiber stock, and the resulting finely divided binder and the individualized fibers may be dispersed into air or gas for a felting operation, as by introducing it into a fiber-settling chamber.

provided by other means as by the application of high frequency dielectric heating.

In Fig. l of the drawing, I indicates any suit-f 10 able defibering apparatus into which fiber stock in felted sheet, fiocculent, or chip form may be introduced at l l. Pulverized or comminuted matrix-forming material may be introduced into the apparatus IU through duct I2. The resulting finely divided binder and individualized fibers preferably homogeneously mixed, are conveyed from the machine through the duct I3 into a settling chamber It in which the commingled binder and iibers are dispersed as indicated at IE. The fibers and binder settle upon an endless receiving member such as a screen i6 and form a low density mat indicated at il. The density of the mat will vary depending on the conditions under `which the fibers and binder material are deposited. For example, the density will be greater if the velocity of the bers and the binder material is increased by projecting the same downwardly into the chamber rather than horizontally as indicated. Likewise the use of a suction box l beneath the screen will accelerate the descent of the fibers and binder material and increase the initial density of the resulting mat to some extent.

In passing the fibers and the heat-softenable matrix-forming binder material through the debering mill I0, sufficient air is introduced into the mill not only to provide an adequate dispersion of the individualized fibers within the settling chamber, but to prevent a rise of temperature within the mill sufficient to soften the binder to the extent that it may become tacky, inasmuch as it is desirable to effect a substantially uniform distribution of loose binder particles throughout the initially formed mat Il.

.The mat Il shown in Fig. 1 when deposited in a gravity settling chamber may have a density of about onepound per cubic foot. Such a mat being fluffy in texture and without substantial strength-giving interfelting of the constituent bers, cannot be handled freely Without rupture and without tending to disturb the uniformity of the binder distribution within the fiber mass. For the purpose of integrating the mat while immobilizing the distributed binder particles within the mat, the particles are activated to adhesiveness to cause the same to adhere to the contiguous fibers. This is the first functioning of the matrix material, and its first binding function. Such softening of the particles may be effected by passing the mat through a heating zone which may be provided by a blower I9 having an outlet 20 which directs a gentle stream of hot air downwardly through the porous mat as shown in Fig. l, while avoiding mechanical dislocation of the particles.

Where the matrix material is thermoplastic, as distinguished from being thermosetting, the application of heat may be prolonged, as in an oven. But where it is thermosetting, and where continued exposure to heat causes loss of plasticity, the heating step should be rapid to avoid advancing the material too far toward its final set. Hence a passage of hot air through the mat is preferred- A Suitable softening temperature may be Since the binder material is of a character that is softenable by heat. the hot air owing through the fibers renders the binder particles tacky and unites the fibers at multitudinous points within the ber mass, thus giving substantial strength to the mat and immobilizing the binder particles to prevent migration of the latter through the mass and loss thereof from or stratification within the lower portion of the mat. By preserving the original distribution of the particles or masses Within the mat. the original ratio of fibers to binder material is not altered by handling and cutting the material for placement in the dies or molds, nor by using sections of less than the original thickness, nor in making use of scraps of the plastic-liber composition in molding operations.

The mat may be compressed during the heatactivation of the binder, or thereafter. 'Ihus the thickness is variable from that of the thickness at formation, to lesser values effected by conipression. It is also pointed out that the binder material which is softenable by heat may be in a stage where it acts like a pressure-activated ad.- hesive, so that adequate mechanical compressing or densifying of the mat will eiect the desired binding action. This is considered to be a binding action under activating conditions of temperature and pressure between binder and fiber.

The heating of the mat by a current of hot gas for effecting a softening or advancing of the binder to render the same adhesiive is facilitated by the low density and resulting porosity of the dry fiber mass. As a result dislodgment and loss of the adhesive particles, when the mat is subsequently subjected to vibration or impacts in handling or in further processing, is avoided.

The fiber mass as initially formed Awithin the chamber being of relatively low density, preferably is preformed or densied before use in molding operations. The densication of the matincreases its strength and better enables it to withstand handling without disintegration, whether it is to be marketed in sheet, roll or other form. The reduction of bulk better adapts the mat for use in conventional plastic forming dies in subsequent molding operations.

Preforming or densification of the bonded mat may be accomplished by passing the same between compression rollers, between platens or in presses, or the mats may be cut up into sections and the pieces compressed in preforming dies which give them the shape required for fitting into final or finishing dies that mold the sections into final form. The temperature and hence the adhesive condition of the binder during densication of the mat is a control over the physical properties of the resulting preform. In Fig. 1 of the drawing the mat il is shown passing beneath a preforming or compressing roll 2l which very materially reduces its bulk, effects further interfelting of the fibers and produces a relatively smooth-surfaced blanket 22 which constitutes a prefor of the plastic-fiber composition of the present invention. The preforming of the mat by compression may be effected with or without heat and may be varied in degree depending on the intended uses of the preformed blanket or molding material. Where the final molded product is to be in sheet form. for example, the preforming and nal compression steps may be combined in one or in successive operations and the relatively low density mat I1 may thus be converted into a relatively dense,

to escape-readily therefrom, .or shift position 10 therein, it is a mat of low density for the step of employing heat to` immobilize the binder relative to fiber. y Y

When marketed in blanket form, the preform can be cut to proper size and shapes for use in 15 dies and compressed to hard final form in a manner similar to the use of conventionalfpowdered or granular plastic composition. If desired, instead of preforming or densifying the mat I1 into the form of a sheet 22, the fmaterial maybe cut 20 to size and the pieces placed in preforming diesV to shape themfor fitting later inthe finishing dies which complete the formationof the molded products. For example, in Fig. 2 of the drawing, .there `is shown-va' shaped preform 23 courg5 has been heat-treated to immobilize-tli'e`- particles" 30 within thenberinass'it may bedensinedby semi.'Y

molding to the form shownin Fig. 2, .orzit'may be f compressedin sheetv formas shown'in Flg.,-1, the jv sheets beinglatercut up'in necessaryshapes and' already a preform, niaygbe additionally com-` A pressed orshaped-ebypressure orheat-andpressure," toprovide va. kdiierentg-preform. for example, f thatofFig.2.;fu- Y Y* Uotiie'ifitec, .riquesof haiidiiiig .ihepiasuc-nber o mat may .b'e'employedlwithin the scopeof thev present improvements. 1 The preformed blanket 22, or the semi-formed article such as that shown in Fig. 2, preferably given adensity thatA represents a substantial f reduction in` the bulk of '45 the initially formedl fiber mat and provides a product which, while flexible,` can be handledV without likelihood of rupture, and which vcan be cutinto shape subsequently-when desired for placement in moldsV or` dies for` nal molding op so erations. The preformingl or densification lpreferably is such-as to reduce the original-bulk substantially and effect material inter-feltingVV of the fibers to give` strength to the mat, but is less than that which gives the material such rigidity that 55 fracturing will occur during subsequent handling or molding operations. A density cof from 4 to 40 pounds of plastic fiber composition per cubic foothas been found suitable for the commercial saleable preform-having by weight 65% no fiber and 35% binder. l i

The invention embraces, in addition to the use of asettling chamber and related apparatusdescribed above, other methods of depositingV the plastic fiber composition in low density mat form. 65

perature of the bonding material, 'or-at the same 7o or higher temperature, from which fmachine'the fiber material issues in clottedbulk form with the granular material vdistributed with high uniformity therethrough wher'ertjhas" nfot softened, or

of'fFig. 2 intoVv dividualization of the fibers is secured by passing the fibers and the material through a Prater Mill to a cyclone collector from which the fibers issue in individualized form and with the granular 5 bonding material distributed throughout the fiber stream. This stream may be passed to a high-velocity, low-concentration pneumatic feeder which delivers the ber-binder dispersion `to a suitable felt forming apparatus as between two endless wire screens of a low-pressure felter whichrforms a mat of the deposited fiber-binder material, theA mat having a density preferably from 3 to 4 pounds per cubic foot. The lowdensity mat may then be heat treated, as above described, to activate the matrix or bonding material to adhesiveness and 4render it immobile relative to the mat which thereafter, or concurrently with the heat treatment, may be densified, as by roll compression, to provide a preform felt of a density of from 4 to 40 pounds per cubic foot. The preform thus provided is ready to be marketed as such and may be converted, by hot pressing, for example. into hard board or into various molded products.

If desired the bers and distributed binderv or material, instead of being delivered by the blower to a gravity chamber, as first above described, may be delivered to a collector which feeds the composition of fibers and distributed granular binder material tov a 'picker roll spreader which "deposits'the bers and binder material onY a suitable` endless belt or wire screen receiver to form a mat of less than 1 pound'per cubic 'foot density. The matmay then be ,roll-compressed to about 3 Sizes fOrI-uS-.in' themas! diesf l'-fheblanket V35 poundsfper cubic `foot density and `riait-treated `sified to provide a-preform of from 4 to 40 pounds density, for example, 1'5 pounds Vper cubic foot.

,The above illustrated or described modes of, and apparatus for, providing Vfibers in individualized form fromv which the low density, porous mat is initially formed are but illustrative, rathery than limitative, of the present invention. If desired, the method may be employed in practicing the present improvements wherein fibers are maintained in circulation at a suitable velocity in a closed or a substantially closed system and from a portion of which system individualized 'fibers may be withdrawn intermittently o r continuously for deposition in mat formor for delivery to a pressure packing unit.

In using the improved plastic-fiber composition in three dimensional molds where the stock comprises sulphite fiber and a binder material, the following procedure may be employed if desired: The fiber stock, in the presence of a solid phenolic resin, may be passed through a Prater mill to individualize the fibers and comminute the resin to a suitable fineness, and is then passed through a cyclone collector. The individualized fibers and a distributed binder or matrix material may then be collected in a gravity depositing chamber or by other apparatus for heat treatment to fix the binder and thence fed to a blower which delivers the fiber-matrix material to a .pneumatic or other packing station where a felt of suitable density, such as 2 pounds per cubic foot, is deposited in a three dimensional mold. The composition in the mold may thereafter be v compressed, with or without applied heat de-V pending upon the character and temperature of the binder present, to a preform having a density anchored to the berwherezit hasy softened. Inv1I of from 4 to 40 pounds to render it handleable 'f without objectionable disintegration for use in a final or finishing mold which by hot pressing densiiies the preform into the final comercial or usable product.

In the description of the above mentioned preforms and the method of making the same, heatsoftenable bonding materials have been contemplated, but the use of pressure-sensitive bonding materials may be employed, and where pressure'sensitive materials are used, initial densification of the bers employed, depending on characteristics desired in the final product, can be effected by use of pressure alone unaccompanied by the application of extraneous heat. Certain forms of rubber, pitch, bituminous compositions and coal tar resins are known examples of materials that exhibit plastic fiow and adequate adhesiveness under pressure to render them useful as binders in the formation of preforms and as matrix formers in high pressure molding of the preforms into final products.

The quantity of binder employed as well as the character of the binder may be varied in accordance with desired characteristics of the final molded product. Where the quantity of phenolic type binder, all of which is fiowable, is approximately 35% or more of the total weight of binder and cellulosic ber, the material can be converted by heat and pressure by conventional plastics practices into hard, dense, glossy products, wherein the resinous component predominates supercially ano; constitutes a matrix for the fibrous component. Where the final product has no voids, the said 35% content of fiowable binder is approximately the critical content between a fibrous surface at a less usage, and a resin surface at a higher usage. It has been found that the initial bonds provided by the bonding particles with the brous component of the material just mentioned are released sufficiently by the heat in hot compression molding to enable the fibers more freely to participate in the flow of material within the dies under the molding pressures, thus filling mold spaces with fiber and resin, where such mold spaces were not previously filled by the preform.

The present method distinguishes from, and possesses advantgaes over, the water suspension method of mat formation referred to above. In the latter method, partial hydration of the fibers generally occurs which renders them mutually adherent whereby they tend to bond together in a mass of greater or less density, depending on the applied pressure. In the present invention which contemplates the formation of nbers in a non-hydrated condition, the fibers are mutually non-adherent, but are caused to adhere by use of the bonding and matrix-forming additive supplied to, and distributed throughout the low density mat, preferably concurrently with the formation of the mat. The heat softenable bo'nding material of the present invention thus liberfates the bonded fibers of the preform under the influence of the heat of molding operations to avoid rupturing the fibers within the mold under the applied molding pressures.

The preferred perform is one which is compressed after or during the initial integration of the mat materials by heat. However, regardless of the exact technique of employing heat or pressure or both, the moldable integrated mat of ber and thermally-moldable binder, is, generically, the preform of the present invention.

The present application is a division of ap- 8 plicant's Serial No. 563,209, filed November 13. 1944, now abandoned.

I claim: l. The method of making moldable preform material containing hot-moldable binder and vegetable' fibers, which comprises continuously depositing upon a moving receiving member from a gaseous suspension entities of dry finely divided solid heat-softenable binder and dry substantially individualized vegetable fibers and thereby forming them into a loose unbonded mat having a density not over 4 pounds per cubic foot. said fibers and binder being in proportion to form a cold rigid body after hot-molding at substantially maximum compression, said solid binder being normally non-adhesive and capable of softening to a condition adhesive to the fiber at an elevated temperature to which the fibers may be heated without destruction of their fibrous character, and bonding the fibers of the mat to form a structure having a density ranging from said density of formation to a density up to about pounds per cubic foot by applying heat at a nonfusing temperature for the binder and of intensity to eiect surface-tackiness of said binder, whereby to unite the fibers one to another by said individual binder entities and to fix the major portion of all the originally separate entities of the original mat into a resultingly strengthened bonded mat.

2. The method of making moldable preform material containing moldable binder and vegetable fibers, which comprises continuously depositing upon a moving receiving member from a gaseous suspension entities of dry finely divided solid heat-softenable binder and dry substantially individualized vegetable fibers and thereby forming them into a loose unbonded mat having a density not over 4 pounds per cubic foot, said bers and binder being in proportion to form y a cold rigid body after hot-molding at substantially maximum compression, said solid binder being normally non-adhesive and capable of softening to a condition adhesive to the fiber at an elevated temperature to which the fibers of the mat may be heated without destruction of their fibrous character, bonding the fibers of the mat to form a structure having a density of not over 4 pounds per cubic foot by applying heat at a nonfusing temperature for the binder and of intensity to effect surface-tackiness of said binder, whereby to unite the fibers-one to another by said binder entities and to fix the major portion of all of the originally separate entities of the original mat into a resultingly strengthened and flexible bonded mat, and thereafter compressing the mat to any density from 4 to about 40 pounds per cubic foot for use as a molding preform.

3. The method of making moldable preform material containing moldable binder and vegetable bers, which comprises continuously depositing upon a moving receiving member from a gaseous suspension entities of dry finely divided solid heat-softenable binder and dry substantially individualized vegetable fibers, and thereby forming them into a loose unbonded mat having a density not over 4 pounds per cubic foot, said bers and binder being in proportion to form a cold rigid body after hot-molding at substantially maximum compression, said solid binder being normally non-adhesive and capable of softenin'g to a condition adhesive to the liber at an elevated temperature to which the fibers may be heated without destruction of their fibrous character, bonding the fibers of the mat to form a structure having a density of notgover 4 pounds per cubic foot by applying heat atV a non-fusing temperature for the binder and of intensity to eiect surface-tackiness of said binder, whereby to unite fibers one to another by said binder entities and to x the major portion of all of the originally separate entities of the original mat into a resultingly strengthened and flexible bonded mat, and thereafter converting said mat into a moldable preform at any density from 4 to about 40 pounds per cubic foot by compression at a tackiness-producing temperature.

4. The method of making moldable preform material containing moldable binder and vegetable bers, which comprises continuously depositing upon a moving receiving member from a gaseous suspension entities of dry finely divided solid heat-softenable binder and dry substantially individualized vegetable bers and thereby forming them into a loose unbonded mat having a density of less than 4 pounds per cubic foot, said fibers and binder being in proportion to form a rigid cold body after hot-molding at substantially maximum compression, said solid binder being normally non-adhesive and capable of softening to an adhesive condition on the fiber at an elevated temperature to which the fibers may be heated without destruction of their fibrous character, bonding the fibers of the mat to form a structure having a density less than 4 pounds per cubic foot by applying heat at a non-fusing temperature for the binder and of intensity to effect surface-tackiness of said binder, whereby to unite bers one to another by said binder entities and to fix the major portion of all of the originally separate entities of the original mat into a resultingly strengthened and iiexible bonded mat, and thereafter compressing the mat to any density from 4 to about 40 pounds per cubic foot for use as a molding preform.

5. The method of claim 1 wherein the fibers are derived from Wood and wherein thereare by weight at least 35 parts of said binder to 65 parts of said fiber, whereby the mass at the ultimate density of maximum compression is substantially a solid body.

6. The method of claim 2 wherein the bers are derived from wood and wherein there are by weight at least 35 parts of said binder to 65 parts of said ber, whereby the mass at the ultimate density of maximum compression is substantially a solid body.

7. The method of claim 3 wherein the fibers are derived from wood and wherein there are by weight at least 35 parts of said binder to 65 parts of said fiber, whereby the mass at the ultimate density of maximum compression is substantially a solid body.

8. The method of claim 4 wherein the bers are derived from wood and wherein there are by weight at least 35 parts of said binder to 65 parts of said iiber, whereby the mass at the ultimate density of maximum compression is substantially a solid body.

CLARK C. HERITAGE.

REFERENCES CITED The following references are of record in the file of this patent:

, UNITED STATES PATENTS Number Name Date 758,246 Goldman Apr. 26, 1904 1,461,337 Weiss July 10, 1923 1,923,195 Finck Aug. 22, 1933 2,057,167 Sherman Oct. 13, 1936 2,288,072 Collins June 30, 1942 2,372,433 Koon Mar. 27, 1945 

1. THE METHOD OF MAKING MOLDABLE PREFORM MATERIAL CONTAINING HOT-MOLDABLE BINDER AND VEGETABLE FIBERS, WHICH COMPRISES CONTINUOUSLY DEPOSITING UPON A MOVING RECEIVING MEMBER FROM A GASEOUS SUSPENSION ENTITIES OF DRY FINELY DIVIDED SOLID HEAT-SOFTENABLE BINDER AND DRY SUBSTANTIALLY INDIVIDUALIZED VEGETABLE FIBERS AND THEREBY FORMING THEM INTO A LOOSE UNBONDED MAT HAVING A DENSITY NOT OVER 4 POUNDS PER CUBIC FOOT, SAID FIBERS AND BINDER BEING IN PROPORTION TO FORM A COLD RIGID BODY AFTER HOT-MOLDING AT SUBSTANTIALLY MAXIMUM COMPRESSION, SAID SOLID BINDER BEING NORMALLY NON-ADHESIVE AND CAPABLE OF SOFTENING TO A CONDITION ADHESIVE TO THE FIBER AT AN ELEVATED TEMPERATURE TO WHICH THE FIBERS MAY BE HEATED WITHOUT DESTRUCTION OF THEIR FIBROUS CHARACTER, AND BONDING THE FIBERS OF THE MAT TO FORM A STRUCTURE HAVING A DENSITY RANGING FROM SAID DENSITY OF FORMATION TO A DENSITY UP TO ABOUT 40 POUNDS PER CUBIC FOOT BY APPLYING HEAT AT A NONFUSING TEMPERATURE FOR THE BINDER AND OF INTENSITY TO EFFECT SURFACE-TACKINESS OF SAID BINDER, WHEREBY TO UNITE THE FIBERS ONE TO ANOTHER BY SAID INDIVIDUAL BINDER ENTITIES AND TO FIX THE MAJOR PORTION OF ALL THE ORIGINALLY SEPARATE ENTITIES OF THE ORIGINAL MAT INTO A RESULTINGLY STRENGTHENED BONDED MAT. 